Development of copper recovery process from flotation tailings by a combined method of high‒pressure leaching‒solvent extraction

Efficient recovery of zinc and copper from copper smelting slag (CSS) by cooperative modification with a composite medium of FeS-O2

Efficient recovery of valuable metals from copper smelting slag (CSS) can not only alleviate the pressure from resource scarcity, but also has important practical significance for the realization of green and sustainable production in the copper smelting industry. In this paper, a composite medium of FeS-O2 is used as a synergistic modifier to transform the solid-state valuable metals in CSS into leachable state of sulphates, and achieves efficient and comprehensive recovery of zinc and copper through neutral leaching. XRD, FTIR, XPS, etc and comparative analysis methods are used to deeply analyze the characteristics of occurrence phase and transformation rules of valuable metal in CSS, roasted slag and leached slag. The results show under the optimal roasting conditions of TRoasting = 650 °C, M(copper slag): M(FeS) = 1:1, V(O2): V(Ar) = 1:6 and tHolding = 90 min, the recovery rate for zinc is approximately 95.1 %, and that for copper is 99.3 %, almost all of which is recovered. These findings provide a new method and process foundation and theoretical support for the efficient resource utilization of CSS.

Reclamation of iron and copper from BCL slag in Botswana

High-grade copper ores have been depleted over the years, making it a challenge in the mining industry. This investigation focused on a methodology to recover iron (Fe) and copper (Cu) from a copper/nickel slag obtained from the Bamangwato Concession Limited (BCL) mine in Botswana. In this modified flotation approach, the Response Surface Methodology (RSM) was used in conjunction with the Central Composite Design (CCD) and Analysis of Variance (ANOVA) to obtain the best optimal flotation conditions for the recovery of iron and copper. Using the RSM - CCD methodology, the optimal predicted responses were illustrated by a coefficient of determination R2 = 0. 9839 for recovery for Fe and 0.9655 for recovery for Cu. The recovery of copper increased with the increasing dosage of Na2S and collector dosage, while the increase of pH, had a decrease in recovery of copper due to the decline in the stability of the froth, which led to the resistance to form stable bubbles for efficient recovery of copper. Selective flotation of copper and iron was achieved by varying the Na2S dosage to achieve maximum recovery. Under these flotation conditions of PAX (800 g/t), pH (8), -75 μm, sulfurizing agent (Na2S, 1000 g/t), flotation time of 8 min, pH regulator of NaOH and H 2 S O 4 and Methyl Isobutyl Carbinol (MIBC) from the experimental runs merited a grade upgrade of Cu in froth concentrate from 0.581 mass% to 0.884 mass%. An enrichment ratio of 2 was realised, with the recovery of Cu being 62%, whereas Fe in the froth concentrate increased from 69.8 mass% to 71.8 mass%. The main aim was to upgrade the grade and recovery of copper and iron to enhance the recovery for copper and iron in the next experimental stage of leaching.

The Challenges and Prospects of Recovering Fine Copper Sulfides from Tailings Using Different Flotation Techniques: A Review

Flotation is a common mineral processing method used to upgrade copper sulfide ores; in this method, copper sulfide mineral particles are concentrated in froth, and associated gangue minerals are separated as tailings. However, a significant amount of copper is lost into tailings during the processing; therefore, tailings can be considered secondary resources or future deposits of copper. Particle–bubble collision efficiency and particle–bubble aggregate stability determines the recovery of target particles; this attachment efficiency plays a vital role in the selectivity process. The presence of fine particles in the flotation circuit is because of excessive grinding, which is to achieve a higher degree of liberation. Complex sulfide ores of markedly low grade further necessitate excessive grinding to achieve the maximum degree of liberation. In the flotation process, fine particles due to their small mass and momentum are unable to collide with rising bubbles, and their rate of flotation is very slow, further lowering the recovery of target minerals. This collision efficiency mainly depends on the particle–bubble size ratio and the concentration of particles present in the pulp. To overcome this problem and to maintain a favorable particle–bubble size ratio, different techniques have been employed by researchers to enhance particle–bubble collision efficiency either by increasing particle size or by decreasing bubble size. In this article, the mechanism of tailing loss is discussed in detail. In addition, flotation methods for fine particles recovery such as microbubble flotation, column flotation, nanobubble flotation, polymer flocculation, shear flocculation, oil agglomeration, and carrier flotation are reviewed, and their applications and limitations are discussed in detail.

Chemical Composition Data of the Main Stages of Copper Production from Sulfide Minerals in Chile: A Review to Assist Circular Economy Studies

The mining industry has faced significant challenges to maintaining copper production technically, economically, and environmentally viable. Some of the major limitations that must be overcome in the coming years are the copper ore grade decline due to its intense exploitation, the increasing requirements for environmental protection, and the need to expand and construct new tailings dams. Furthermore, the risk of a supply crisis of critical metals, such as antimony and bismuth, has prompted efforts to increase their extraction from secondary resources in copper production. Therefore, improving conventional processes and developing new technologies is crucial to satisfying the world’s metal demands, while respecting the policies of environmental organizations. Hence, it is essential that the chemical composition of each copper production stage is known for conducting these studies, which may be challenging due to the huge variability of concentration data concerning the ore extraction region, the process type, and the operational conditions. This paper presents a review of chemical composition data of the main stages of copper production from sulfide minerals, such as (1) copper minerals, (2) flotation tailings, (3) flotation concentrates, (4) slags and (5) flue dust from the smelting/converting stage, (6) copper anodes, (7) anode slimes, (8) contaminated electrolytes from the electrorefining stage, (9) electrolytes cleaned by ion-exchange resins, and (10) elution solutions from the resins. In addition, the main contributions of recent works on copper production are summarized herein. This study is focused on production sites from Chile since it is responsible for almost one-third of the world’s copper production.

Bioleaching Process for Copper Extraction from Waste in Alkaline and Acid Medium

Flotation wastes are becoming a valuable secondary raw material and source of many metals and semimetals worldwide with the possibilities of industrial recycling. The flotation tailings contain oxide and sulfide minerals that have not been sufficiently stabilized and form acidic mine waters, which in turn contaminate groundwater, rivers, and reservoi6sediments. An effective way to recycle these mine wastes is to recover the metals through leaching. While the focus is on acid bioleaching by iron- and sulfur-oxidizing bacteria, alkaline leaching, and the removal of iron-containing surface coatings on sulfide minerals contribute significantly to the overall environmental efficiency of leaching. For this study, static and percolate bioleaching of copper from flotation waste at the Bor copper mine in Serbia was investigated in alkaline and then acidic environments. The aim of the study was to verify the effect of alkaline pH and nutrient stimulation on the bioleaching process and element extraction. A sample was taken from a mine waste site, which was characterized by XRF analyses. The concentration of leached copper was increased when copper oxide minerals dissolved during alkaline bioleaching. The highest copper yield during alkaline bioleaching was achieved after 9 days and reached 67%. The addition of nutrients in acidic medium enhanced the degradation of sulfide minerals and increased Cu recovery to 74%, while Fe and Ag recoveries were not significantly affected. Combined bioleaching with alkaline media and iron- and sulfur-oxidizing bacteria in acidic media should be a good reference for ecological Cu recovery from copper oxide and sulfide wastes.

Submarine Tailings in Chile—A Review

This review aims to understand the environmental impact that tailings produce on the land and marine ecosystem. Issues related to flora, fauna, and the environment are revised. In the first instance, the origin of the treatment and disposal of marine mining waste in Chile and other countries is studied. The importance of tailings’ valuable elements is analyzed through mineralogy, chemical composition, and oceanographic interactions. Several tailings’ treatments seek to recover valuable minerals and mitigate environmental impacts through leaching, bioleaching, and flotation methods. The analysis was complemented with the particular legislative framework for every country, highlighting those with formal regulations for the disposal of tailings in a marine environment. The available registry on flora and fauna affected by the discharge of toxic metals is explored. As a study case, the “Playa Verde” project is detailed, which recovers copper from marine tailings, and uses phytoremediation to neutralize toxic metals. Countries must regularize the disposal of marine tailings due to the significant impact on the marine ecosystem. The implementation of new technologies is necessary to recover valuable elements and reduce mining waste.

Leaching of iron from copper tailings by sulfuric acid: behavior, kinetics and mechanism

Copper tailing is a widespread and intractable solid waste in copper production. Traditional leaching and recovery technology for copper tailing focuses on copper but neglects the leaching of iron. With the increase in applications and demands of iron-containing materials for environment, understanding the leaching behaviors of iron can promote the utilization of copper tailings. In this study, the kinetics and mechanism of the leaching of iron from copper tailings using sulfuric acid were studied. Under optimal conditions (40 °C, sulfuric acid concentration of 0.53 mol L⁻¹, stirring speed of 400 rpm, solid/liquid ratio of 1 : 10 and leaching time of 120 min), 66.45% of Fe, along with 65.32% of Zn and 59.95% of Cu, were leached from the tailings. The leaching of iron was confirmed to be controlled by solid-film diffusion. The reaction orders for sulfuric acid concentration, solid/liquid ratio, and stirring speed were found to be 0.85, −0.70, and 0.40, respectively. Results from XRF, XRD, and SEM indicated that oxides (including CaO, CuO, and ZnO) were leached first, after which Fe₂SiO₄ was preferentially reacted compared to Fe₃O₄. The accumulation of CaSO₄ and SiO₂ inhibited the further leaching of iron.

Leaching behavior of copper tailings with sulfuric acid was expounded. Leaching was optimized: 1 M H₂SO₄, S/L of 1 : 10, T = 40 °C, 120 min. Fe₂SiO₄ was preferentially leached than Fe₃O₄. Leaching of Fe is controlled by solid-phase diffusion.

The effect of cationic surfactants on improving natural clinoptilolite for the flotation of cesium

Flotation using cationic surfactants has been investigated as a rapid separation technique to dewater clinoptilolite ion exchange resins, for the decontamination of radioactive cesium ions (Cs⁺) from nuclear waste effluent. Initial kinetic and equilibrium adsorption studies of cesium, suggested the large surface area to volume ratio of the fine zeolite contributed to fast adsorption kinetics and high capacities (q_c = 158.3 mg/g). Adsorption of ethylhexadecyldimethylammonium bromide (EHDa-Br) and cetylpyridinium chloride (CPC) surfactant collectors onto both clean and 5 ppm Cs⁺ contaminated clinoptilolite was then measured, where distribution coefficients (K_d) as high as 10,000 mL/g were evident with moderate concentrations CPC. Measurements of particle sizes confirmed that adsorption of surfactant monolayers did not lead to significant aggregation of the clinoptilolite, while < 8% of the 5 ppm contaminated cesium was remobilised. Importantly for flotation, both the recovery efficiency and dewatering ratios were measured across various surfactant concentrations. Optimum conditions were found with 0.5 mM of CPC and addition of 30 μL of MIBC frother, giving a recovery of ∼90% and a water reduction ratio > 4, highlighting the great viability of flotation to separate and concentrate the contaminated powder in the froth phase.

Automated Identification of Mineral Types and Grain Size Using Hyperspectral Imaging and Deep Learning for Mineral Processing

In mining operations, an ore is separated into its constituents through mineral processing methods, such as flotation. Identifying the type of minerals contained in the ore in advance aids greatly in performing faster and more efficient mineral processing. The human eye can recognize visual information in three wavelength regions: red, green, and blue. With hyperspectral imaging, high resolution spectral data that contains information from the visible light wavelength region to the near infrared region can be obtained. Using deep learning, the features of the hyperspectral data can be extracted and learned, and the spectral pattern that is unique to each mineral can be identified and analyzed. In this paper, we propose an automatic mineral identification system that can identify mineral types before the mineral processing stage by combining hyperspectral imaging and deep learning. By using this technique, it is possible to quickly identify the types of minerals contained in rocks using a non-destructive method. As a result of experimentation, the identification accuracy of the minerals that underwent deep learning on the red, green, and blue (RGB) image of the mineral was approximately 30%, while the result of the hyperspectral data analysis using deep learning identified the mineral species with a high accuracy of over 90%.

A critical review on environmental implications, recycling strategies, and ecological remediation for mine tailings

Mine tailings, generated from the extraction, processing, and utilization of mineral resources, have resulted in serious acid mine drainage (AMD) pollution. Recently, scholars are paying more attention to two alternative strategies for resource recovery and ecological reclamation of mine tailings that help to improve the current tailing management, and meanwhile reduce the negative environmental outcomes. This review suggests that the principles of geochemical evolution may provide new perspective for the future in-depth studies regarding the pollution control and risk management. Recent advances in three recycling approaches of tailing resources, termed metal recovery, agricultural fertilizer, and building materials, are further described. These recycling strategies are significantly conducive to decrease the mine tailing stocks for problematic disposal. In this regard, the future recycling approaches should be industrially applicable and technically feasible to achieve the sustainable mining operation. Finally, the current state of tailing phytoremediation technologies is also discussed, while identification and selection of the ideal plants, which is perceived to be the excellent candidates of tailing reclamation, should be the focus of future studies. Based on the findings and perspectives of this review, the present study can act as an important reference for the academic participants involved in this promising field.

Chitosan-grafted tetrapolymer using two monomers: pH-responsive high-performance removals of Cu(II), Cd(II), Pb(II), dichromate, and biphosphate and analyses of adsorbed microstructures

For circumventing the cumbersome and expensive multifunctional and multipolymer adsorbents for high-performance removals of hazardous water-contaminant(s), chitosan-g-[2-acrylamido-2-methyl-1-propanoic acid (AMPS)-co-2-(3-acrylamidopropanamido)-2-methylpropane-1-sulfonic acid (APAMPS)-co-2-(N-(3-amino-3-oxopropyl)acrylamido)-2-methylpropane-1-sulfonic acid (NAOPAMPS)-co-acrylamide (AM)] (i.e., chitosan-g-tetrapolymer), a multifunctional scalable and reusable hydrogel, was synthesized by grafting of chitosan and in situ attachments of N-H functionalized NAOPAMPS and APAMPS hydrophilic acrylamido-monomers during free-radical solution-polymerization of the two ex situ added AMPS and AM monomers in water. The response surface methodology was employed to synthesize one hydrogel envisaging the optimum balance between swelling and stability for the superadsorption of Cu(II), Cd(II), Pb(II), Cr₂O₇^2-, and HPO₄^2-. The in situ attachments of NAOPAMPS and APAMPS, grafting of chitosan into tetrapolymer, structures and properties, pH-responsive abilities, superadsorption mechanism, and reusability were understood via in depth microstructural analyses of adsorbed and/or unadsorbed chitosan-g-tetrapolymer(s) through ¹H/¹³C NMR, FTIR, XPS, TGA, XRD, DLS, and pH_PZC. The maximum adsorption capacities of Cd(II), Cu(II), Pb(II), Cr₂O₇^2-, and HPO₄^2- were 1374.41, 1521.08, 1554.08, 47.76, and 32.76 mg g^-1, respectively.